Control system for electric welders



Sept. 1, 1936. J. v. CAPUTO CONTROL SYSTEM FOR ELECTRIC WELD ERS Filed June so, 193:5

ll SheetS Sheet l INVENTOR J. V CAPUTO Sept. 1, 1936.

CONTROL SYSTEM FOR ELECTRIC WELDERS Filed June 59, 1933 11 Sheets-Sheet 2 NW M UNQ NNW :ZYENTOR 1 4,

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' CONTROL SYSTEM FOR EL CTRIC WELDERS ll Sheets-Sheet 3 Filed June so, 1933 INVENTOR @WN W a? Sept. 1, 1936.

v. CAPUTO 2,052,965

CONTROL SYSTEM FOR ELECTRIC WELDERS Filed Jl me so, 1955 11 Sheets-Shes?- 5 INVEN'ITOR AZ a h v f f wwg Sept. 1, 1936. J. v. CAPUTO CONTROL SYSTEM FOR ELECTRIC WELDERS Filed June 30, 1933 ll Sheets-Sheet 6 NW Wk New INVENTOR Sept. 1, 1936. .1. v. CAPUTO V CONTROL SYSTEM FOR ELECTRIC WELDERS ll Sheets-Sheet '7 Filed June 50, 1953 mum INVENTOR -4 mag o u 0 NM Sept. 1, 1936.

J. v. CAPUTO I CONTROL SYSTEM FOR ELECTRIC WELDERS 11 Sheets-Sheet 8 L F iled June 30, 1955 yin 210R w? Sept. 1, 1936. J. v. CAPUTO CONTROL SYSTEM FOR ELECTRIC WELDERS Filed June so, 1933 11 Sheets$heer. 9

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CONTROL SYSTEM FOR ELECTRIC WELDEHS Filed June 30, 1935 ll Sheets-511661- 11 71, 122a FJ' FZZ. 68a 69 7062 X Q Q W n ay a m a,

INVENTO R Patented Sept. 1, 1936 UNITED STATES PATENT OFFICE CONTROL SYSTEM FOR ELECTRIC WELDERS My invention relates to electric welding and, in particular, to a system for automatically controlling the operation of an electric welding apparatus and associated mechanism.

Electric welding devices have heretofore been operated almost entirely under manual control. These devices are of large size, especially when designed to weld large articles such as pipe having a diameter of 24 inches and a length of to 50 feet. It will be obvious that a large force of operators is necessary to control apparatus of this size properly and. that it is difficult for an operator at one portion of the machine to know what conditions are in other portions thereof.

My invention provides automatic means for controlling the operation of a welding machine of even the largest size and makes it possible for a single operator to have all parts of the machine under his individual control at all times, as well 20 as providing definite information as to the conditions in all parts thereof.

Continuous resistance welding as practiced heretofore has been effected almost universally by the aid of alternating current. Because of the continuously varying character of alternating current, a weld produced thereby usually lacks perfeet continuity. For this reason, I prefer to employ direct current so as to obtain a weld which is entirely continuous and perfectly uniform. as

r a source of current, I employ a homopolar generator. I control the voltage of the generator both by varying its excitation and bychanging the speed at which it is driven. For the purpose of providing a wide variety in generator speed, it

drive the generator by a variable speed motor and supply the motor with current from a variable voltage generator.

The current is conducted to the worlr by means of an electrode comprising two insulated disc-like to conducting members having suitable connections to the generator. In order to equalize the wear on the disc-like electrode members, I provide means actuated by the work for reversing the polarity of the generator at intervals between the passage ofsuccessive pieces of work through building up of the voltage. In order to terminate lo the welding current promptly, 1 apply a small reverse excitation to the generator so that its voltage rapidly decreases to zero at the proper time.

Numerous auxiliary devices, such as forming rolls, feed rolls, planishing rolls and sizing rolls, l5

are usually incorporated in a pipe welding device. I provide a generator for supplying current to the motors driving such auxiliaries. E control the speed of the auxiliaries first by varying the volt age of the generator and then by individual control of each motor. She operation of the auxiii aries is governed by a single manual controller within reach of the operator of the apparatus. Since it is sometimes necessary to reverse the forming rolls, feed rolls, etc., provide means for reversing thepolarity or the generator supplying current to the auxiliary motors. it is not de sirable to reverse the electrode motor with the other auxiliaries while a blank is traversing the welder, because of the possibility of injury to the electrode resulting from engaging the extruded burr on the welded seam. it therefore provide means to lift the electrode out of contact with the work upon reversal of the auxiliaries or in any other emergencies, such as failure of power when a blank is in the welder.

I also provide means for automatically con trolling the voltage of the welding generator dur-- ing a welding operation and for automatically controlling the speed of the auxiliaries. This means comprises a master frequency generator and means for comparing the frequency generated thereby with frequencies characteristic of the operation of the other elements or" the apparatus. I also provide means for safeguarding the apparatus against abnormal conditions of various kinds. The operation of the various elements, furthermore, is suitably interlocked so that it is impossible to effect an improper sequence of may be made within the scope of my broader claims. In the drawings:-

Figures 1 through 5, when positioned relative to each other, as will be described later, constitute a circuit diagram partly in the complete form and partly schematic, of the system of my invention, illustrating the various elements thereof in somewhat the general relative position they will occupy in an actual installation;

Figures 6 through 10, when placed together relative one to another in a manner to be described. constitute a diagram, almost entirely schematic, in which the circuits to the various elements shown in Figures 1 through are illustrated in simplified form;

Figure 11 is a partial schematic view illustrating certain of the subject matter of the preceding figures to an enlarged scale in simplified form;

Figure 12 is a similar view of another portion of the system;

Figure 13 is a diagrammatic view illustrating a modified form of apparatus for controlling the welding current;

Figure 14 is a side elevation of one of the control devices employed in the system;

Figure 15 is a sectional view along the line XV-XV of Figure 14;

Figure 16 is a schematic showing of the proper location of Figures 1 through 5 to constitute a complete diagram;

Figure 17 is a diagrammatic view illustrating the proper placing of Figures 6 through to constitute the schematic diagram; and

Figure 18 is a partial modification shown diagrammatically.

It will be understood that the several elements of a single control device, a relay, for example, will be shown in different parts of the schematic circuit in order to simplify the connections. The actual moving parts of the control devices may thus sometimes be duplicated, being shown both in the circuits which they control and in operative relation to the devices by which they are actuated.

General arrangement of the power apparatus and auxiliaries The general arrangement of the power apparatus for generating, controlling and distributing the welding current may best be observed in Figures 1 through 5, when positioned relative to one another as indicated in Figure 16.

The welder proper is shown at it and comprises a shaft-mounted electrode it supported in bearings l2 suspended from a frame 93. The adjustment of the bearings i2 is controlled by suitable screws driven by a motor it. Current is supplied to the electrode it from a generator is. The generator is preferably of the homopolar type having a field structure partially indicated at it, an armature ll composed of a plurality of inductors, slip rings is, and brush rigging i9. Opposite terminals of the generator 45 are connected to an electromechanical coupling 26 comprising a shaft 28 which is coupled through universal joints to the shaft on which the electrode H is mounted, and electrical connections including slip rings 22, brush assemblies 23, bearings 24, and spaced, flexible, connecting cables 25. The bearings 24 are similar to the bearing 92 and each comprises a disc mounted in antifriction bearings having conducting members extending axially therethrough but insulated therefrom. A motor 26 drives the shaft 2!.

The generator I5 is driven by a motor 21 which is preferably a shunt-wound, direct-current motor. The motor 2! derives energy from a generator 28 connected thereto. A motor 29, preferably of the synchronous, alternating-current type, is directly coupled to the generator 28 to drive the latter and a flywheel 30 is preferably mounted on the shaf t for a purpose which will appear later. Electrical energy is supplied to the motor 29 from a supply circuit 3! through a circuit breaker 32.

In addition to the main power generator and transmitting units above mentioned, I provide other apparatus for controlling the speed of the motor 26 driving the welder electrode, and all other motors driving auxiliary devices, such as forming rolls, sizing rolls, feed rolls and finishing rolls. This equipment includes a motor 33 preferably;similar to the motor 29. The motor 33 is connected to the supply circuit 3| through a circuit breaker 3B and is mechanically coupled to a generator 35 which is preferably a direct-current generator capable of the necessary adjustment for generating a variable voltage. A flywheel 36. is mounted on the shaft of the motor 33. The motor 33 also drives a generator 31 for supplying energy to a control bus having conductors 3B and 38'. Exciter generators 39 and it are also driven by the motor 33 and supply excitation for the field windings of the generator 28 and the motor 2?.

For satisfactory welding, it is necessary to vary the magnitude of the welding current in accordance with the speed of travel of the pipe blanks past the electrode. I effect the desired control of the welding current by comparing the frequency of the output of an alternating-current generator driven at a speed proportional to that of the movement of the blanks through the welder, with the frequency of the output of a generator driven at a speed proportional to the magnitude of the welding current. The master-frequency generator is illustrated at t! and is driven by a motor 62 connected directly across the terminals of the generator 35 by conductors 62m and 42g. An altemating-current generator at is coupled to a motor At which is preferably of the direct-current type, difierential-compound wound. A synchronous motor 65 is also coupled to the motor 66 to drive the generator 33 in the intervals between successive passages of pipe blanks through the welder, at which times the motor M is not energized.

For cooperating in the speed control of the motors of the various auxiliaries, of which it will be understood there are a plurality similar to the motor 26, I utilize for each auxiliary motor, such as 28, a generator 46 driven thereby through a variable speed drive 61. The manner in which the generator 56 cooperates withthe master frequency generator ii in controlling the speed of the motor 26 will become apparent as the description proceeds.

Starting operation of the system breakers 32 and 34 are closed to insure continuous operation of the motors at rated speed. A circuit breaker 31a is closed by the energization oi. its closing coil 31q, controlled by push buttons and motor 21.

spasms fit and 311;, relay 3110 and an interlock "a on a relay 43 in the generator field circuit. .As the motor 33 accelerates, the voltage of the control generator 31 builds up across the buses 38, 33'. The generator 31 has a shunt field 31! and a series field 31:, as well as a shunt field rheostat 311. The operating winding of a relay 48 is connected in series with the shunt field 31) and the rheostat 311- across the terminals of the generator 31. The excitation for the motor 33 is obtained from the buses 38, 38' which are shown connected to the slip rings of the motor through a suitable rheostat.

Accelerating the motor 33 to normal operating speed also causes the exclter generators 39 and 0 to supply limited current to the shunt field windings 28) and 21! of the generator and motor 28 and 21, when suitable excitation is provided for the generator field windings 39) and 40f. The excitation of the field windings of the generators 39 and 40 is controlled by the adjustment of a dual rheostat 49 which is normally in such position as to cause the generator 28 to drive the motor 21 at the normal speed of the generator IS. The rheostat has two resistance elements 49a and 49b and two wipers 49c and 49:1. The rheostat is actuated by a motor 49m having forward and reverse field windings 59f and 491 connected in series with limit switches 49L adapted to be actuated by the wipers in their extreme positions. The exciter generator 39 has a field winding-39f which is connected in series with a protective resistor 39',- and the resistance element 590, of the rheostat it, across the buses 38'. The field winding it of the exciter generator it? is similarly connected across the buses 38, in series with a resistor eeiand the resistance element t9?) oi the rheostat 59. The field windings 3t, and do; are normally short-circuited by back contacts 58:1: and 5th! of a relay 58 (see Figure 6). The relay 59 also has iront contacts the and 59b eiiective when the relay winding is energized to shunt resistors 397' and M31. After the motor has been started and until the winding of the relay has been energized, therefore, current flows from the bus 38, through parallel circuits, one including the wiper 58c, the back contact titer and the resistance 39/", the other including wiper 5%, back contact 56y and resistance MT. The rheostat 19 is shown in normal position, and full excitation will be supplied to the generator 28 and the motor 2? when the relay 59 operates, and

the generator it will, thereupon, be started and.

driven at full speed.

Relays 5i and 52 have their windings connected in series with the circuits just described but are not operatively energized until the relay 5B is operated to shunt resistors 391' and 401'. Similar relays 53 and 5d have their windings connected in series with the shunt fields 28 and 2%. A relay 55 has its operating winding connected in series with the armatures of the generator 28 The relay 55, in common with most of'the other relays to be described, has a shunt holding coil 55s which is energized by the operation of the relay and, while not strong enough to operate the relay, is strong enough to hold it in operated position once it has been actuated by its main winding 55.

When it is desired to supply normal excitation to the generator 28 and motor 21 preparatory to starting the latter, the relay 50 must be ener gized by pressing a push button 56 (see Figure 6). Operation of the push button 56 completes a circuit from the conductor 33 of the control bus through a back contact 352: of the relay 55, the

contact 56b of the push button, the winding of the relay 50, the contact 56a of the push button 56, to the conductor 38'. The operation of the push button 56 also completes a circuit through back contact 552: and contact 56b through the winding of a relay 5! and a centrifugal switch l5c driven in accordance with the speed of the generator IS. The relay 5! is thereby operated.

The energization of the winding of the relay 53 causes contacts 50:: and 50;! to open, and contacts 50a and 50b to close. The field windings 39! and 40f are now energized to a degree dependent upon the adjustment of the rheostat 43 and relays 5| and 52 are operated. The excitation of the field windings causes the generators 39 and 40 to supply exciting current to the shunt field windings 28! and 21) of the generator 23 and the motor 21. The generator 28 builds up its voltage and starts the motor 21. This current also traverses the windings of the relays 53 and 54 to energ ze the latter. The operation of the relays SI, 52, 53, 54 and 5? completes a locking circuit for the relay 50. This circuit extends from the conductor 38 through back contact 553, contact 570:, the winding of the relay 50, contacts iiia and 52a, contacts 53a and 54a, to the conductor 38'. This circuit remains closed as long as the relay 55 is not energized suificiently to open its 9 contact 55 nor the relays ti through 5t deenergizecl. The relay 55 is set to operate only upon the now of a predetermined, excessive current from the generator to the motor as in case of an overload.

Excitation has now been supplied for the generator 28 and the motor 2? the former has been started and supplies driving current the latter. Thus the motor 2? driving the generator i5 is accelerated to bring the generator up to speed.

Welding generator esccitatz'on When the welding generator to has been brought up to speed, the generation of welding generator (it? which is directly coupled to the driving motor A switch operated by an electro magnet controls the connection of the battery 55 alternately to the field windings 351 and the charging generator. The battery is connected to the generator held during the interval when a pipe blank is passing through the welder, to supply to the welding generator the excitation needed to insure that suiiicient welding current is delivered. In the intervals between successive passages of pipe lengths through the welder, the battery is connected to the charging generator. Automatic means are provided for cutting off the battery from the generator when it is sufflciently charged.

The switch 5i has four front contacts Gla, Gib, tile and Bid, and four back contacts Slw, 6'3), Sly and tie. These latter contacts are normally engaged as illustrated in Figure 2. In this position, one terminal of the battery 58 is connected through the contact 6 1:0 to the lower brush of the generator 60. The other terminal of the battery is connected through the contact 6lw, a. shunt 52, a series coil 63s and the back contact of a reverse current cutout 53 to the upper brush oi the generator 813. The cutout 63 has a shunt coil 630 connected across the generator 60 and the purpose of the cutout is to protect the battery against any possible reversal of the polarity of the generator to. The shunt field winding of the latter is shown at 601, the field rheostat at fiflr and the series winding at 69s.

I provide what is, in effect, an ampere hour meter for measuring the time thebattery 58 is on charge, as well as the time it is on discharge. This device comprises a motor it having its armature connected through the back contacts My and ii 22 of the switch 6i across the shunt 62. The voltage across the armature 56, therefore, is proportional to the current fiowing through the shunt. The field M of the motor is connected across the armature of the generator 59 in series with a rheostat 3 37 and the series coil 53s and contact of the reverse current cutout. The motor 5 2 drives a screw shaft 65 on which a traveling nut 66 is threaded. While the battery is being charged, the motor at drives the shaft 65 in a direction such as to move the nut 66 toward the left, and vice versa. When the battery has been fully charged, the traveling nut db actuates a contact 8? to complete a circuit from the bus 38' through said contact and the operating coil of the switch 6i to the bus 38. The switch at then operates to close the contacts em, bib, bio and bid and open contacts 65w, 86.13, My and tile. The opening of the contacts Eiw and bias breaks the charging circuit and the opening of the contacts big and biz disconnects the motor B3.

The energization of the operating coil of the switch 6i prepares a circuit between the storage battery 58 and the shunt fields N3 of the generator iii. The polarity of the exciting current, however, is controlled by the switch 59. This circuit extends from one terminal of the battery 58 through contact Sla, a shunt 62a, a front contact 59a of the switch 59 to (but not through) a resistor 88, through a back contact 691: in parallel with the field windings Iii in series, through a resistor 58a, a filter 10 including condensers 'lllc and an inductance 70a, front contacts 591) of the switch 59, a series holding coil 59s and thence by a conductor 590 to rheostat i513 and through a motor operated rheostat H, from which the circuit extends by conductor lie to contact tllb of the switch GI and thence to the other terminal of the battery 58. This circuit may be more easily observed-in Figure 11. It will be apparent from the foregoing description that the field windings 45 are connected across the resistor 88 by the contact 69:1: of the contactor 69 and that the battery is connected to the field windings to supply a limited excitation of the predetermined polarity. The motor 66 is thereby operated at creeping speed in the discharge direction. This polarity is opposite that of the excitation supplied during a welding operation on the energization of the contactor 69, and is effective to reduce the welding voltage promptly to zero.

The welding generator has now been started and supplied with a limited excitation insufiicient to generate the normal welding voltage, and until a pipe blank is fed past the electrode ll, furthermore, no current will flow from the generator l5.

aosaess When current actually begins to flow from the generator IS, an exclter generator I51: having its field winding in series with the generator 15, will be excited to produce a compound excitation. The generator I51 is'driven at a constant speed by a motor 95m and is connected to the series field windings 85s of the generator l5 by a circuit similar to that through which the field windings l5 are connected to the reversing switch 59. The circuit can be observed more clearly in Figure 12. The circuit for the series field windings 85s extends from thearmature of the generator 95:1: through a filter circuit 10 similar to that shown at it], through a rheostat l5r", a back contact 691:, which is closed when the coil 69 is deenergized, through the field windings its in parallel with a rheostat l5?" and thence to the other side of the generator armature through a resistor 68b and a back contact 69y of the contactor 69. A resistor 58a parallels the circuit winding H58 and the portion of the circuit therefor last described.

When the contactor 69 is actuated, the circuit-for the windings lbs extends through the rheostat tor, a front contact 690', the windings We in parallel with which is connected the adjusting rheostat Hir, and a contact 69a to the other terminal of the armature. It will be apparent that the direction of current through the windings 55s is reversed upon operation of the contactor 69. The field winding is normally connected across a resistor 58, and the resistors 68a and 68b are of such value that a predetermined reverse current will fiow through the series field upon deenergization .of the contactor $9, to assist in reducing the welding generator voltage to zero.

The starting of the auxiliary motors-preliminary operations When the welding generator has been started, the next step in the operation of the system is to advance a pipe blank to the welder. This requiresthat the motors driving the forming rolls, feed rolls, pressure rolls (if driven), planishing rolls and sizing rolls, and the electrode motor, be started to forward the blank to and through the welder. As already stated, these motors are all driven by current supplied from the generator 35. Since the motor and its control apparatus is duplicated for each auxiliary device, I have shown the complete circuit for only one motor.

It will be understood, of course, that similar equipment will be provided for all other motors. The motor having its circuit illustrated in complete detail is the motor 26 driving the electrode.

All the auxiliary motors are started simultaneously by controlling the excitation of the generator 35. As a preliminary step, however, it is necessary to close a push button switch for each motor to be started. Examples of these push buttons are shown at E2 and F3 in Figure 10, these being the push buttons for controlling the motors 26 and 42. These push buttons are provided with a mechanical hold-down mechanism which keeps the contacts closed until manually released. Instead of push buttons, of course, any other type of manual switch may be employed.

Operation of the push button 12 completes the circuit from the bus 38 through contact 12a of the push button, a back contact 14:: of a relay 14, a limit switch 15, contact 121) of the push button the operating coil of the relay 16, to the bus 38'. The relay l6 closes its front contact 16a. The closing of this contact establishes a holding circult including a contact 120 of push button 12, for the coil of relay 16. The circuit extends from the bus-38 through contact 120, contact 16a, and the coil of relay 16. The winding of the relay I4 is connected directly across the armature of the generator 35 but since the field of the latter has not yet been excited, there is no voltage to operate the relay and the contact 143: remains closed. The limit switch 15 is closed by the operation of a rheostat 11 similar to the rheostat 49, for controlling the excitation of the generator 35. The limit switch I5 may be similar to the switches TIL controlling the circuit of the motor lim which operates the rheostat Tl, except that the limit switch 15 is closed only when the rheostat is in such position as to insert the full resistance thereof in series with the shunt field oi the generator 35 shown at 35 Operation of the push button 73 is efiective to energize a relay l8 and complete a holding circuit therefor at its front contact 78a in the same manner as already described for the relay 56. Additional push buttons and relays are provided, of course, for each of the auxiliary motors incorporated in a complete operative welder.

The connection of the various motors to the generator 35 is controlled by the push buttons, such as ":72 and "i3. The electrode motor 2%, for example, is adapted to be connected to the terminals of the generator 35 icy buses and through a contactor Elia, the operating coil 39 of which is controlled Toy the relay F6. The circuit of the coil "i9 also includes an i terlocu which is closed by a reversing swltii only when the latter is operated so as to cause generator to generate voltage of a polarity such as to cause rotation of the auxiliary motors to move a pipe length forward through the welder. When the reversing switch M is in the other po= sition for shooting reverse movement or a blank. for any reason, the interlock lilo is opened. @nly the electrode motor of all the auxiliaries, is controlled by the interlock Silo.

circuit or the contactor coil is also con trolled by a relay in series with the field winding of the motor mindin is her really energized. as soon as the generator connected to the buses 38, 33' rd the relay Bl, therefore, immediately closes its contact Sic. A centrifugal switch responsive to speed of the electrode motor is also in circuit of the coil "l9.

Since reversing switch is normally neutral or central position, interlock. we open and the circuit oi he coil l9 of the ccntactor lilo is not completed until the reversing switch as is shifted in the proper direction. cir= suits for the coils of the contactors of all other auxiliaries are completed, however, as in the example now to he described.

A contactor 32o. controls the connection of the auxiliary motor 42 driving the master-freoucncy generator l l, across the buses 35c and 3%. The cont-actor is operated by a coil 52 controlled by the push button and the relay J8. relay 83 in the field circuit of the motor and a contrifugal switch iZa responsive to the speed of the motor 42, both of which are normally closed, complete the circuit for the coil 52 after the operation of the relay l8. lhe energization of the coil 82 actuates the contactor 82a to connect the motor 42 across the buses 35a and 35b.

The field windings of all the auxiliary motors are normally connected across the buses 38 and 38. In Figure 10, for example, the rleld windlugs 28! and 42f of the motors 26 and 62 are connected directly to the buses 38, 38' through manual switches 26s and 42s. When the welder is shut down, these switches are opened and their back contacts shunt the field windings through protective resistors 26?) and 4222. When all the auxiliary motors except the welding motor 26 are connected across the terminals of the generator 35, it is then only necessary to excite the shunt field winding of the latter to generate voltage to start the auxiliary motors.

lhe voltage generated by the generator 35 and maintained across the buses 35a and 35b is determined by the degree of excitation of the shunt field winding 35 of the generator. The degree of excitation of the field winding is controlled by two rheostats in series therewith, a rheostat 84 drivon by a motor t im and the rheostat ila driven by a motor Tim. The function of the rheostat 84 is to insert suflicient resistance in the field circuit to reduce the excitation practically to zero. The function or" the rheostat lie is to vary the voltage actually generated by the generator 35 when the rheostat 85 is in the minimum resistance or shunted position. The rheostat thus serves instead or? a switch for deenergizing the shunt field 35;, and is normally maintained in its maximum resistance position Toy means which will now be del orward operation of auxiliaries A controller adapted to be manually oper ated, governs forward and reverse movement of a. blank through the welder. The controller has ilxeo lingers a, b, c, a, e, n and r, and movable tion of the 1 across the auxiliary motor supply and before any oi" these motors be connected. to the buses.

in; the same time, a circuit is completed for the shunt operating coil a relay the main winding of wh is connected in series with the field winding of generator This circult includes a limit switch 552, closed when rheostat lid is in maximum resistance position, a hack contact of a relay the main nding of which is in series with the main winding of the relay S6, and winding The relay Ell also has a shunt operating winding ills. The shunt operating windings She and ills are different from the shunt holding coils of the overload relays previously mentioned in that they are strong enough to operate the relay and hold it in operated position.

A preliminary necessary to the effective operation of the controller in either direction is the closing of a push button switch This complates a circuit from the bus 3d through finger 85s, segment 5357 and finger 85b of the controller Elli, the push button switch 83, the winding of a relay 89, a back contact a: of a relay 9i] connect" ed in series with the shunt field winding 35f, a back contact of the relay it connected across the armature or the generator 35 and a limit switch 15a which, like the limit switch l5, previously described, is closed only when the rheostat 84 is in the maximum resistance position. 0n the completion of this circuit, the relay 89 closes its contact 89a to energize the operating coil 9! of a circuit breaker 9| a which, when closed, connects the generator 35 across the buses 35a and 85b. The circuit through the coil 9| extends also through a back contact 551 of the relay connected in series between the generator 28 and the motor 21, through a plurality of overload relays 0L associated with the various auxiliary motors and centrifugal switch l5c responsive to the speed of the welder generator IS. A contact 88x associated with contact 88a (see Fig. 6) opens the circuit to the shunt holding coils of the overload relays to permit their proper resetting in case they have operated in response to abnormal conditions.

As soon as the coil 9! is energized, the circuit breaker em closes and operates its auxiliary contacts. A holding circuit for the circuit breaker is completed by one of these auxiliary contacts 9lb. The circuit extends from the bus 38 through a front contact 92a of a relay 92 which is normally energized in a manner to be described later, a stop push button 93 having a normally closed contact, the auxiliary 9lb which is closed when the circuit breaker 94a closes, a front contact 86a of the relay 86 which is closed by the energize.- tion of the coil 88s,* as previously described, a front contact 94a of a relay 99 responsive to the voltage of the main power circuit 3 l, and a holding coil 85r for the controller 85, to the coil 9|. The function of the holding coil 851' is to hold the controller 85 in the forward position when it has been manually actuated thereto. If all the re lays and protective devices are in proper position, the above described holding circuit for the coil 9| is completed and the breaker 9m remains closed. The generator 35 is now actually connected to its buses 35a and 35b and the various auxiliary motors are connected to the same buses. It remains only to provide suitable excitation for the generator 35 to start up the auxiliary motors. To accomplish this result, it is necessary to shift the controller 85 to the forward position indicated by the dotted line F.

When the controller 85 is moved to the forward position, a circuit is established from the bus 38, through finger 85a, segment 85;, segment 85k and finger 850, a limit switch 84L, to the forward field winding 85; of the motor 89m and thence to the bus 38. The motor 84m then operates to shift the rheostat 84 to the minimum resistance position. A similar circuit including segment 85t and-finger 851' is also established for a relay 95. This circuit is completed through a limit switch 15:: which may be on the same shaft as the switches 15 and 15a but is designed to close its contacts when the rheostat 84 moves away from the maximum resistance position. The relay 95 closes its own locking circuit through its contact 95a and the limit switch 151:.

The movement of the controller 85 also establishes a circuit, as above described for relay 95, for contactor operating coils 98 and 91. The contacto' 95 opens a back contact 96:: to break a normall closed shunting circuit including a protective resistor connected across the field winding 35]. The contactor 97 closes a contact 91a to connect the circuit of the field winding 35] to the bus 38'. This circuit is now complete except for the operation of the reversing switch which nor mally occupies a central, open-circuit, position.

A circuit for a coil 88} of the swit'ch80 is also completed by the movement of the controller. This circuit extends from the bus 38 through finger segment 85f, segment 85m, finger 85d to the coil 80] and thence to the bus 38'. The energization of the coil 80 of the reversing switch 88 causes the latter to close its front contacts 88b and 800 to connect the shunt field 35f across the buses 38 and 38'. The interlock 88a. is also closed by the energization of the coil 80 (see Fig. 10) and the coil '39 is thereby energized to close the contactor 39a to connect the motor 26 across the buses 35a and 35b. The other auxiliary motors have already been connected to these buses by the operation of their push buttons similar to that shown at l3. A relay 98 is also energized through a circuit in parallel with that of the coil 88f. The circuit for the coil 98 is completed through the limit switch 151:. The operation of the relay 98 closes its front contact 98a to complete a locking circuit therefor and for the coil 8f through the limit switch 75x.

As the voltage of the generator 35 builds up, the auxiliary motors accelerate simultaneously to the speeds for which they are individually adjusted in a manner to be described later.

The completion of the circuit for the field winding 35 f which causes the generator 35 to drive the auxiliary motors, energizes relay windings 86, 81 and 90. The energization of the winding 86 has no effect since its contact 86a was already closed by the energization of the winding 86s. 'The energization of the winding 81 opens contact 81.1: and closes contact 81a. The opening of the contact 81:2: opens the circuitfor the coil 86s but the contact 85a does not open since it is held closed by the energization of the coil 86. The closing of the contact 81a completes a locking circuit for the v winding 81.9 which is maintained as long as the controller is in forward position. The energization of the winding opens contact 901: to deenergize relay 89 if it has not already previously been deenergized by the release of the push button 88.

In the normal course of events, a flat plate will be fed to the former and thereby formed into a cylinder. This tubular blank will then be forwarded by feed rolls to the welder, where its edges are seamed by a welding operation, and then passed through sizing and finishing rolls in the known manner. Before describing the cycle of events which takes place upon the advancement of a blank to the welder, however, I wish to point out certain additional operations of the mechanism controlling the operation of the auxiliary motors.

Stopping the auxiliaries If it is desired to stop the operation of the auxiliary motors without opening the main circuit breaker 9Ia connecting the generator 35 to its buses, a push button 85s may be operated to shunt the holding coil 851' of the controller 85. The controller is spring biased to its neutral position and upon the deenergization of the holding coil, immediately returns to said position.

If it is desired to open the circuit breaker 9la as well as stop the auxiliary motors, the stop button 93 is actuated to open the circuit for the holding coil 851' and the operating coil 9| in series. The deenergization of the coil 9|, of course, will open the circuit breaker 9la. When the controller 85 is restored to neutral or central position, the holding circuit for the coil 81s is broken. The contact 81a opens and contact 81a: closes if the contactor 97a is opened. The originally described iii) circuit for the reverse field winding 841' of the motor 84m is completed and the motor operates to shift the rheostat 84 to the maximum resistance position. This deenergizes relays 86, 81 and 90, even if the contactor 91a. remains closed.

The relay 95 and the coils 9B and 91 are, however, maintained energized through the contact 95a of the relay 95 the holding circuit of which is completed through limit switch 153:. The relay 98 also maintains its own locking circuit through contact 98a and limit switch 15a: and maintains the energization of the coil 80] until the limit switch l5x is opened, indicating that the rheostat 84 is in the maximum resistance position. The relay 98 then opens its contact 98a to deenergize the coil 80f and open the contacts 80a, 80b. and 890.

When the rheostat 84 is moved to the maximum resistance position, the opening of the limit switch 75:: also breaks the locking circuit of the relay $5 and the circuits of coils 95 and 91 maintained thereby. The contact 95:0 closes to shunt the field winding of the generator 35 and the contactor lilo: opens to disconnect the field 35} from the bus 38'. By the operation of the rheostat 8 and the opening of the contact lilo, as before stated relays til, 53'! and 98 are deenergized. The contact 86a of the relay Bil is thereby opened, as well as the contact Bio of relay til, while the contact Q83: of relay 1% is closed. At the same time, the initial energizing circuit for the coil Bits is restored by the closing of limit switch i512. The circuit of the field winding is now open at contactor ill and the insertion of the rheostat ti l further prevents flow of current therethrough. It will thus be apparent that even after the restoration of the controller to the neutral position, the contactor File and the contacts tlilb and we remain closed and the contact 9 5x remains open until the current through the field circuit has been reduced substantially to zero by operation of the rheostat St to maximum resistance position.

Ii current tends to flow through the generator 35 in the reverse direction, by reason of the momentum of the auxiliary motors and the equip= merit driven thereby tending to drive the motors as generators, the relay 5352 will operate to energlee the coil to operate a contactor 35k and shunt th series winding t the same time,

contactor 351i will be opened by the deenergization of coil 352). The polarity of the winding 355, which thus placed in circuit, is such as to cause the generator 35 to develop a strong, counter electroraotive force opposing the voltage gen erated by the auxiliary motors operating as gencraters. The flow of excessive currents through the generator is thus prevented. relay 352 has an armature connected across the shunt 35p in series with the generator and a field winding 35m connected across the control bus.

Reversing the auxiliaries When it is desired to reverse the auxiliary motors, the controller 85 is moved to the reverse position indicated by the dotted line R. As in the case of the forward movement of the controller, a circuit is established through the forward field winding 85) of the motor 83m. The circuit is from the bus 38 through finger 85a, segment 35f, segment 85g, finger 85c, limit switch 84L to the field winding. 84), and through armature Mm, to the bus 38'. The rheostat 84 is thus operated from its maximum resistance to its minimum resistance position, in which the switch 84L opens the circuit just described to stop the motor. A circuit is similarly completed through segment 85s and finger 85r to energize the winding of relay 9!, through the limit switch 15.1, which is closed as soon as the rheostat 84 moves away from the maximum resistance position. The relay 95 closes its holding circuit through contact, 95a and the coils 96 and S! are also energized thereby with the result that contact 962: is opened and contact 91a is closed.

Automatic electrode lift contact Zi'ib which is closed when the contactor SM is closed, to the bus 38. At the same time, a circuit is completed through controller segment 85p and finger 8571 through an auxiliary contact did closed when the contactor 37a is closed, and a switch ids which is normally closed to the operating coil of a relay tilt and thence through the contacts of overload relays 0L and auxiliary contact Elli) to the bus The operating coil tell opens a contact lithe which normally shunts the armature oi t..c motor it across a dynamic braking resistor. The coil 99 operates the switch i lr to close contacts 9% and 9% to energize the screw motor id. The motor may be accelerated automatically by known starting systems including starting contactors 'ldgo and Mg. Operation of the motor i i, of course, drives the screws which effect vertical adjustment of the electrode ii. The operation of the motor resulting from the closing of contacts 9% and 99b is such as to raise the electrode out of engagement with the pipe blank. l 'l is connected across the mill supply MS through the front contacts like and ldilh of a spring-closed switch which is normally main tained in the illustrated position by a shunt holding coil Hi2. ply, the deenergization or" the coil permits contacts M323: and i921 to close, connecting the screw motor i l across the control buses 38, 38. A series holding coil tilts holds the switch in open position until it is manually re-closed upon restoration of the voltage on the circuit MS. "in this way, power is always available for the eleration of the electrode and, in case of the stoppage of the tube blank in the welder, which would result in injury to the electrode, the system is always operative automatically to lift the elec trode out of contact with the work. Various means for effecting this operation will be described later. The control circuits for the motor M are likewise transferred to the mill supply by the operation of auxiliary contacts of the contactor (lid, on the opening of the latter. A manual switch dip, closed after the system is started, completes the transfer circuit.

The motor l6 continues to operate until the adjusting screws are raised sufiiciently to actuate the switch Him to open contacts Ma: and lie and close contacts Ma. The opening or" contacts Ma: breaks the circuit for the coil 99 and the contacts 99a and 99b of switch Mr are thereby The motor case of failure of the mill supopened to stop the motor I4. The opening of contacts I42 deenergizes the coil I00 and permits the contact I001: to re-close, shunting the armature of the motor I4, for dynamic braking.

It is desirable to raise the electrode not only in case of the stoppage of a blank in the welder but also when reversing the auxiliaries. and it will be apparent from the foregoing that the raising of the electrode is the first step resulting from a reversing of the controller With the electrode raised out of normal operating position, conditions are proper for a reversal of the auxiliaries.

Reversal of polarity of generator driving auxiliarzes The closing of the contacts I411 of the switch Mm extends the circuit previously traced through the auxiliary contact 370 to a coil 801* which is connected directly to the .bus 30 which, when energized, is efiective to move the reversing switch 80 into such position as to reverse the conmotion of the field winding 35 of the generator 35 in its circuit between the buses 38, 38' by closingcontacts 80d and 80a. The closing of the contacts Ma also energizes a relay I 03 through a circuit including the limit switch 151:. This relay closes its contact I03a to complete itsown locking circuit and that of the winding 801'. By

the operation of the switch 80, contacts 80d and 80a of the switch are'closed, and interlock 80a is open, opening the circuit of coil I9 to disconnect the motor 26 from the buses-35a and 35b. The field winding 35f of the generator 35 is thus connected across the buses 38, 38' so as to cause the generator to develop a voltage of reverse polarity which causes the auxiliary motors to reverse. Since the field windings of the auxiliary motors are connected across the buses 38, 38', their polarity will not be changed and the reversal of the voltage across the armatures of the motors will cause them to rotate in the reverse direction.

As the reversed field of the generator 35 builds up, the generator supplies current of correspondingly reversed polarity to the auxiliary motors.

In order to maintain the desired operation of the contactors 35k and 35t under the control of the relay 35.2, I reverse the connections between the relay and the operating coils 35h and 3522 of the contactors by means of a reversing switch 80', the operation of which is co-ordinated electrically or mechanically with that of the reversing switch 80. The relay 352 and the twin series field windings of the generator 35 thus operate in the same manner to protect the generator armature against excessive current, regardless of the reversed polarity of the field winding.

When the contacts 80d and We are closed to connect the field winding 35 in circuit, the relays 86, 81 and operate in a manner already described in connection with the actuation of the controller to the forward position.

When it is desired to stop reverse rotation of the auxiliary motors, the controller 85 is restored to its neutral position. The circuit for the reverse field winding 841' of the motor 84m is again completed and the rheostat 84 moves to the maximum resistance position to deenergize the field winding 35f. The limit switch 153: is thereby opened and the locking circuit for the coil 801' and the relays and I03 is opened. The coils 96, 91 being thus deenergized, the contact 963: closes and the contact 91a opens. The deenergization of the coil 801' permits the reversing switch 80 to assume its neutral position opening the contacts 00c and 80d. It is to be noted that no contactors .are opened until the generator field current is reduced to zero by rheostat 84, since the relay I03 maintains a holding circuit for the contactor operating coils until limit switch I51: opens.

Lowering the electrode If it is now desired to resume forward operation of the auxiliary motors, the controller may be thrown to the forward position with the results previously described. If it is desired to lower the electrode into blank engaging position, this may be accomplished by operating a push button I04. At its contact I04a, the push button completes a circuit for a coil I05 through a limit switch I4w which is opened only when the electrode adjusting screws have reached their final lower limit, and an interlock 99:17 which is closed when the coil 99 is deenergized. At its contact I041), the push button completes a circuit for the coil I00. The coil I05, when energized, causes the reversing switch I4 to close its contacts I050. and I05b to reverse the screw motor I4. As the reverse operation of the screw motor starts, contacts I4a are opened and contacts I41: and I42 are closed. The opening of contacts I4a has no effect. since the coil 80r controlled thereby has already been deenergized. The closing of the contacts Ma: is likewise without eifect, as is the closing of the contacts I 4.2, since the circuit for the coil I00 is completed through the contact I04b of the push button I04. The push button at I04, obviously, must be held closed throughout the downward operation of the screw motor I4. When is is released, the coils I00 and I05 are deenergized to stop the motor and apply dynamic braking to the armature by the closing of contact I00x. A push button I00 is similarly effective to raise the electrode under manual control by energizing contactor coils 99 and I00.

Sequence of operations for welding a tube blank In this portion of the description, it will be assumed that the preliminary steps already described have been performed, that the welding generator is being driven, and the auxiliary motors are operating at normal speed. If a flat plate is now fed to the former, it will be bent into tubular shape with its edges abutting, to form a tube blank. The details of the former are not shown since they are already well known. The motor 42 is typical of the motors driving the rolls of the former, feed roll stands, planishing rolls, sizing rolls and the like. After the tube blank has been formed, it is preferably fed to feed rolls with its scam in proper position for engagement by the electrode II.

Automatic polarity-reversal apparatus While the tube is advancing toward the electrode II, a flag switch I0I completes one of two circuits alternatively to hold the reversing switch 59 in one of its two extreme positions. It will embedded in insulation II! through which the projections on the opposite face. Ratchet teeth IIO are formed on the periphery of the disc I for engagement by a detent III. The disc I08 is projections I09 extend.

The switch assembly is rotatably mounted on a shaft H3 in electrical contact with the disc I00. A yoke H4 is rotatable on the shaft H3 and provides amounting for the detent III. The yoke I I4 has insulated contacts I Ma and I I 411 arranged to engage the projections I09 on opposite sides of the disc I 08 alternately. The yoke II4 carries a roller I I5 adapted to be engaged by an advancing tube blank to shift the yoke clockwise. The disc I08, of course, moves clockwise, as shown in Figure 14, with the yoke because of the engagement of the detent III with the ratchet teeth II 0. When a blank passes over the roller I I5, however, the yoke I I4 is reset by a spring without returning the disc I 08.

The device is designed and constructed so that the movement imparted to the disc I09 by the engagement of a blank with the roller II 5 is sunlcient to move the next succeeding projection I09 into positionfor engagement by one of the contacts I Ha, I I4!) when the yoke is retracted by its spring. By this construction, the switch I01 is effective to close one of two circuits alternately every time a blank traverses the welder. The circuit is also maintained closed during periods between the successive passages of blanks through the welder. Assuming the contact I I4a and switch I01 to be closed, a circuit is established (see Figs. 5 and 7) from the upper control bus 38 to the disc I08 of the switch I01 through a slip ring I08a. The circuit then continues through contact II4a and conductor 59k to the winding 59L of the switch 59 and thence returns to the bus 38'.

Initial conditions Itwillbe apparent that the switch I01 thus determines the position of the switch 59 but the latter may be in either position at any given time dependent only on the position of the contacts of the switch I01. As stated earlier in this description, the operation of the switch 59 connects the field windings I5 of the generator I5 in circuit to receive a limited exciting current of a predetermined polarity.

The motor 42 is now being driven at a predetermined speed, the same as all the other auxiliary motors, and drives the generator 4| to provide a predetermined frequency of alternating current on the master-frequency bus 4Ia connected thereto. The motor 45 is drawing energy from this bus through a contactor 45a which is normally in closed position. The generator 43 thus supplies alternating current to a difierential relay IIG, of the same frequency as that supplied directly thereto from the bus Ma. The contacts of the differential relay are therefore in neutral position. The relay is constructed like an induction motor with a wound rotor which moves only when the frequencies of the voltages applied to the rotor and stator difier.

A flagswitch I I1 adapted to be engaged by the advancing tube blank is normally maintained by a spring in position to close its contacts II1a. This switch completes a circuit from the bus 38 through said contacts and a relay IIO to the bus 38'. The relay IIO thus normally maintains its contact IIBa closed. This completes a circuit from the bus 38 through a resistor II9r adapted to be shunted by a contact II9a of a relay II9, a resistor I 20, and the contact I I8a, to the bus 38'.

The contact Illa thus shunts and prevents energization of the operating coil 49 for actuating the contacts 69a, b, c, d, x and 1/, controlling the conziectigzi of the shunt field windings I5 to the batery First steps in welding sequence-initial excitation of welding generator.

When a tube blank advances toward the electrode I I, it engages the flag switch I I1, opens contacts I I la and closes contacts I Ill The relay I I8 is thus deenergized. There is a parallel circuit for this relay through an auxiliary contact 9Iz operated by the circuit breaker 9 Ia, but this auxiliary is open since the circuit breaker is closed. The deenergization of the relay II8 results, after a definite time, in the opening of contact I I 0a which moves the shunt from around the coil 09. The closing of the contact IIIb completes a circuit through an auxiliary contact 9Ic closed when the circuit breaker 9I closes, the coil of a relay H9 and thence to the bus 30'. The relay I I9 is immediately energized and, after a predetermined time,

closes its contacts II9a, II9b, and II9c. The closing of the contact II9a shunts the resistor 91' and causes the energization of the coil 69 to operate contacts 09a, 0, d, a: and y. The contact II9b of the relay II9 completes a circuit through the winding of a relay III. The energization oi the coil I 2 I closes its contact I 2 Ia to shunt the resistor I5r in the circuit of the field windings I5f, which limits the field current while there is no blank in the welder. The contact II9b'also completes a. circuit including contact 8:: for a relay I3I which establishes a parallel circuit for coil I2I, through contact I Ma.

When the coil 69 is energized as described, it opens contacts 69:: and :u, and closes contacts 69a, 09a and 89d. The closing of contact 69d, as previously described, effects energization of the operating coil of the switch 6| to cause the contacts 6Ia and SI!) to close and contacts SIw and Siato open. The field windings I5f are thus connected directly through the contacts 69a and 690 to the circuit extending from the battery 58 through the reversing switch 59. Normal exciting current is thus supplied to the field windings and normal welding voltage is generated. The relays controlling the operation of contactor coil 69 are timed so that normal welding voltage is developed almost immediately upon the engagement of the electrode I I by the blank.

Second step in welding sequence-temporary over-excitation of welding generator As soon as the advancing tube blank engages the electrode, the welding generator supplies current through conductors I5a and I5!) to the welding electrode I I through a shunt 44s to the mechanism shown in Figure 3 for driving the electrode and conducting the welding current thereto.

Welding current immediately starts to flow across the seam in the tube blank. The flow of welding current sets up a voltage across the shunt 448 which operates a relay I23 connected across the shunt in series with a rheostat r, and a differentialcompound winding 44d of the motor 44, through a reversing switch 441-. The operation of the relay I23 closes its contacts I 23a to connect the armature of the motor 44 across the buses 30, 38'in series with a relay I24 and a relay I25. The operation of the relay I24 opens the circuit of the field winding of the motor 45. The operation of the relay I25 disconnects the alternating-current winding of the motor 45 from the generator 4|. 

